After the life size nativity set pieces have been rotationally cast, they are removed from the molds. The molds are made of silicone rubber and fiberglass. The fiberglass mother mold is removed followed by the silicone. Removing the silicone reveals the completed cast stone sculpture. The final finish is then applied to the life size nativity statue making it ready for display. The materials and casting process utilized by ArcStone Casting and Design provides a statue that is suitable for outdoor display and will wear like stone. The images below show the removal of the mold from the nativity ox.
The nativity statues are cast in bonded marble and capture every detail of the original sculpture. Below is the cast statue of the Holy Family, which includes Mary, Joseph, and baby Jesus. The statues are reinforced with fiberglass, and foam in the interior. The material wears just like stone and is designed for indoor or outdoor display. Big Nativity produces the finest nativity sets available.
This is the Big Nativity set by ArcStone Casting & Design. Currently you may order this larger than life size nativity with all of the sculptures seen. We generally fabricate our statues of bonded marble with the life size nativity sets in a white tone as shown on our Gallery page. However as we are the manufacturer, we can produce them in any color or finish. We can also post paint them in full color. We have designed trees and a stable which can also be ordered as part of the nativity set.
The images below are of the actual clay sculptures and are scaled to size. We are currently finishing the molds for these sculptures and will be casting in a few weeks. We are taking orders for Christmas 2013. To receive a pricing sheet please fill out the Contact Us form. We would be happy to talk to you about any kind of custom pieces you may want as part of a nativity, or about large display requests.
The large life size outdoor nativity set continues to make great progress. We have finished sculpting the Ewe, Ram, Lamb, and Ox. The Donkey is nearing completion as is the third wise man. Shown here kneeling. We have some more detail on the hands, face, and clothing which should take about a day. We anticipate to be making molds of all the pieces by the end of the month.
Today we made progress on the nativity Ewe and Lamb Sculpture. We will be finishing this sculpture tomorrow. Grass was added after examining the statue for difficulty of casting. Adding the grass will provide necessary strength to the legs of the sheep, in addition it eliminates most complications with this piece for mold making.
We finished sculpting one sheep of the nativity today. It is tedious work applying the texture. I noticed just a couple of little tweeks I would like to make to the sculpture prior to the mold being put on, but for the most part it’s ready to go. The next sculpture to be completed will be the ewe and lamb, then the donkey, and the ox. After we get the animals out of the way we will complete the work on the human figures.
This shows the Holy Family of the life size nativity.
We have had to take a break from sculpting the Big Nativity to cast some other life size nativity statues. This image shows the finished mold completely assembled which will be placed on the rotational casting machine to create the finished product. The Big Nativity molds will be similar in construction and appearance when completed.
We are adding more and more clay everyday. Some days more than others. I had to do reconstructive surgery on the wise men because I wasn’t happy with the arm position of the left arm of the standing wise man. I knew I had an issue when working with the 18″ maquette, but at the time I was so anxious to move on to scanning and enlarging the sculptures that I let it go. I paid for it by remodeling it with about 100 pounds of clay! Its all part of the process.
Justin has been working on sheep this last week and has given them a great face lift. The clay sheep have been obedient to his every command, sometimes I see Justin giving them little pats on the head. The two kings have a lot of mass and it is a huge sculpture. I have give them their first detail pass by roughing in the faces, hands, and defining their robing. The standing shepherd has received the same treatment. Next in line is going to be Mary, Joseph, and Baby Jesus.
I have included an image of our tool table so you can see what instruments we work with while modeling clay. We use a large tool called a rake to take down the heavy areas of clay which makes the surfaces more even. The low spots are filled in, and it is gone over again with the rake. Smaller tools are used when working around areas such as the face and hands. Enjoy the images. If you want to see the work in progress you can contact me for a tour of the studio.